Volvo 850 Supplement Manual
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Volvo 850 Supplement Manual

a/c-heater system - automatic
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See also: Service Manual , Owner's Manual
1995-96 Auto. A/C-Heater Systems
Volvo 850
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in the AIR BAG RESTRAINT
SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.
CAUTION: When battery or radio is disconnected, radio will go into
anti-theft protection mode. Obtain radio code anti-theft
protection code from owner prior to servicing vehicle.
A/C SYSTEM SPECIFICATIONS
SPECIFICATIONS
¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡
Application
Compressor Type
....................
Compressor Belt Tension (1)
Compressor Oil Capacity
Refrigerant Capacity (R-134a)
System Operating Pressures (3)
High Side
...............
Low Side
....................
(1) - Belt tension is maintained by automatic belt tensioner.
(2) - Use PAG Oil (Part No. 11 61 407-0)
(3) - Pressure switch cut-out points.
¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡
DESCRIPTION
The Electronic Climate Control (ECC) module (A/C-heater
control panel) contains a function selector dial, driver's and
passenger's temperature dials, a REC (recirculated air) switch, A/C
OFF switch, and a fan speed (blower motor) control lever. See Fig. 1.
The heater (blower motor) fan is controlled by ECC output (power)
stage. Air conditioning system will only operate above 32
Blower switch must not be in zero position to allow compressor to
engage.
Other system components include an A/C relay, A/C compressor,
low-pressure switch (pressostat), A/C safety and high-pressure switch,
engine coolant temperature sensor, outside temperature sensor,
interior temperature sensors, and duct temperature sensors.
In addition, driver's and passenger's temperature control
damper motors, recirculation damper motor, floor/defroster damper
motor, ventilation damper motor, and diagnostic connectors (units)
complete system.
A/C-HEATER SYSTEM - AUTOMATIC
1995 Volvo 850
Zexel DKS-15CH 6-cyl.
.....................
..................
406-450 psi (28.5-31.6 kg/cm
25-33 psi (1.8-2.3 kg/cm
Specification
( 2) 6.8 ozs.
26.4 ozs.
¢
)
¢
)
£
£
F (0
C).

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  • Page 1 A/C-HEATER SYSTEM - AUTOMATIC 1995 Volvo 850 1995-96 Auto. A/C-Heater Systems Volvo 850 * PLEASE READ THIS FIRST * WARNING: To avoid injury from accidental air bag deployment, read and carefully follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR BAG SYSTEM procedures in the AIR BAG RESTRAINT SYSTEM article in the ACCESSORIES/SAFETY EQUIPMENT section.

  • Page 2: Air Distribution Control

    Fig. 1: Identifying ECC Control Panel Courtesy of Volvo Cars of North America. OPERATION A/C COMPRESSOR CLUTCH CONTROL The A/C compressor electromagnetic clutch is powered by the A/C relay. Compressor operation requires that the A/C relay be activated by both Electronic Climate Control (ECC) module and Engine Control Module (ECM).

  • Page 3: Damper Motors

    temperature control dial, and engine coolant temperature. At low outside temperatures, the ECC control module selects floor/defrost setting, with a slight amount of bi-level air if £ sunshine is present. If outside temperature is between 50-66 F (10- £ C), a varying degree of bi-level air is selected. At temperatures £...

  • Page 4: Recirculated Air Mode

    RECIRCULATED AIR MODE The ECC control module selects recirculated air mode only for a combination of cooling and high outside temperature, provided that: There is a considerable difference between the desired and actual temperature on driver’s side. The quantity of recirculated air will vary between 70-100 percent, depending on difference in temperature.
  • Page 5 NOTE: Test Unit (981 3190) and Adapter (981 3194) are required for DTC diagnosis. The Volvo Diagnostic Key (998 8670) may be used to perform self-diagnostics. Follow tool manufacturer’s instructions. There are 3 different test modes/settings which can be selected for reading off DTCs.
  • Page 6 Code # Condition/Affected Circuit 1-1-1 ..... No Fault Found By Diagnostic System 1-2-1 ..Outside Temp. Sensor Circuit Shorted To Ground 1-2-2 ........Outside Temp. Sensor Circuit Open Or Shorted To Power 1-2-3 ..Driver’s Side Temp. Sensor Circuit Shorted To Ground 1-2-4 ......
  • Page 7 (2) - Used only with Volvo Diagnostic Key (998 8670). ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡...

  • Page 8: Erasing Codes

    (10 seconds on, 10 seconds off), switch A/C compressor on and off, and turn control panel A/C indicator on and off. If A/C relay does not respond as indicated, check A/C relay. See A/C RELAY CHECK under TESTING. Self-Adjustment Of Damper Motor Limit Positions 1) Turn ignition on.
  • Page 9 Fig. 3: Using Test Unit To Diagnose ECC System Courtesy of Volvo Cars of North America.
  • Page 10 Fig. 4: Identifying Outside Temperature Sensor Terminals Courtesy of Volvo Cars of North America. Fig. 5: Locating Outside Temperature Sensor Courtesy of Volvo Cars of North America.
  • Page 11 No. 3 (Brown wire) and terminal No. 5 (Green or Yellow wire). Resistance should be 8000-12,000 ohms. If resistance is not as specified, replace faulty temperature sensor. Fig. 6: Identifying Passenger Compartment Temperature Sensor Connector & Component Terminals Courtesy of Volvo Cars of North America.
  • Page 12 Fig. 7: Locating Passenger’s Side Temperature Sensor Courtesy of Volvo Cars of North America. DTC 1-2-4 & 1-2-6 DRIVER’S OR PASSENGER’S SIDE TEMP. SENSOR CIRCUIT OPEN OR SHORTED TO POWER 1) Ensure DTCs 1-2-2, 1-2-4, 1-2-6, 2-1-1, 2-2-1, 2-3-1, 2-3- 3 or 2-3-5 are not present at the same time.
  • Page 13 ground wire. If only DTC 1-2-4 or 1-2-6 is present, go to next step. 2) Turn ignition off. Install test unit and adapter between ECC control module and wiring harness. Turn ignition on. Connect voltmeter to test unit pins No. 10 and 12 to check driver’s side temperature sensor and terminals No.
  • Page 14 Fig. 8: Locating Duct Temperature Sensor Courtesy of Volvo Cars of North America.
  • Page 15 Fig. 9: Identifying Duct Temperature Sensor Terminals Courtesy of Volvo Cars of North America. DTC 1-3-2 & 1-3-4 DRIVER’S OR PASSENGER’S SIDE DUCT TEMP. SENSOR CIRCUIT OPEN OR SHORTED TO POWER 1) If DTC 1-3-2 and 1-3-4 are both present, check for open circuit in duct temperature sensor common ground (Brown wire).
  • Page 16 If continuity is not present, duct temperature sensor is okay but an open circuit is present in wiring. Repair wiring for an open circuit. Fig. 10: Identifying ECC Control Module Terminals Courtesy of Volvo Cars of North America. DTC 1-3-5 NO ENGINE TEMPERATURE FREQUENCY SIGNAL...
  • Page 17 1) Run engine and check whether temperature gauge in instrument cluster works. If temperature gauge works, engine temperature signal is reaching instrument panel, but Green/Gray wire between ECC control module terminal A23 and instrument cluster has an open circuit. See Fig. 10. 2) If temperature gauge does not work, temperature sensor wiring may be shorted or engine temperature signal may be absent from engine management system.
  • Page 18 3. Turn damper motor output shaft. Ohmmeter should vary between 0-12, 000 ohms. See Fig. 11. If ohmmeter indicates no continuity, there is an open circuit in damper motor position sensor. Replace damper motor. Fig. 11: Identifying Damper Motor Connector & Component Terminals Courtesy of Volvo Cars of North America.
  • Page 19 Fig. 12: Identifying A/C Relay Connector Terminals Courtesy of Volvo Cars of North America.
  • Page 20 Fig. 13: Removing Damper Motor Courtesy of Volvo Cars of North America. DTC 2-1-2, 2-2-2, 2-3-2, 2-3-4 & 2-3-6 DRIVER’S OR PASSENGER’S SIDE DAMPER MOTOR POSITION SENSOR...
  • Page 21 SHORTED TO GROUND 1) Check if DTCs 2-1-2, 2-2-2, 2-3-2, 2-3-4, and 2-3-6 are all present together. If all DTCs are not present, there is a short circuit in ground wire between ECC control unit and damper motor which applies to DTC. See AUTOMATIC A/C-HEATER SYSTEM DIAGNOSTIC TROUBLE CODES table, then go to next step.
  • Page 22 1) Check if DTCs 3-2-1, 3-2-2, 3-2-3, 3-2-4, and 3-2-5 are also present. If all DTCs are present, vehicle may be equipped with an ECC control module for a right-hand-drive vehicle, or vice versa. Check ECC terminal A28. See Fig. 10. ECC control module for left-hand- drive vehicles should not have terminal A28 grounded.
  • Page 23 See Figs. 14 and 15. Connect an ohmmeter between test unit pin No. 42 and power stage connector terminal 1A. Ohmmeter should indicate continuity. If no continuity is present, check wiring for an open circuit. Fig. 14: Identifying Power Stage Connector Terminals Courtesy of Volvo Cars of North America.
  • Page 24 Fig. 15: Locating Power Stage & A/C Relay Courtesy of Volvo Cars of North America. DTC 4-1-9 ECC POWER STAGE EMITTING FAULTY DIAGNOSTIC SIGNAL...
  • Page 25 1) Ensure ignition is off. Connect test unit to ECC control module. Check ground circuits. See DTC 1-2-1, OUTSIDE TEMP. SENSOR CIRCUIT SHORTED TO GROUND. If ground circuits are okay, go to next step. 2) Turn ignition on. Connect voltmeter between test unit pins No.
  • Page 26 speed. 4) Close engine hood, doors and windows. Run engine at 1500- 1600 RPM. Place thermometer in one of the center panel vents. Allow system to stabilize for at least 8 minutes. Check temperature in center panel vent. See A/C SYSTEM PERFORMANCE SPECIFICATIONS table. A/C SYSTEM PERFORMANCE SPECIFICATIONS (1) ¡...

  • Page 27: Ignition System

    ¨ ¨ ¨ ¨ Digital Timer (Parking Heater) 12 Volts (On); ¨ ¨ ¨ ¨ 0 Volts (Off) © ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¨...
  • Page 28 © ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡ ¡  ¨...

  • Page 29: Solar Sensor

    Voltage should vary by a few millivolts. The higher the intensity, the lower the voltage. If sensor does not operate as specified, there is an open circuit or short to ground in wire or solar sensor. Fig. 16: Locating ECC System Sensors Courtesy of Volvo Cars of North America. SPEEDOMETER SIGNAL...

  • Page 30: Removal And Installation

    1) Raise and support front of vehicle. Perform TEST MODE 2 under TROUBLE SHOOTING. ECC control module should respond to vehicle speed signal with Code 1-1-3. ECC control module will continue to flash code even once TEST MODE 2 is activated. If Code 1-1-3 does not appear, turn ignition off.
  • Page 31 Fig. 17: Identifying Evaporator & Heater Core Connections Courtesy of Volvo Cars of North America. COMPRESSOR Removal & Installation 1) Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove air intake hose and hose connection to fan cover. Remove control box air intake hoses and Electronic Control Units (ECUs) from control box.

  • Page 32: Damper Motor

    Fig. 18: Removing Cooling Fan Components Courtesy of Volvo Cars of North America. CONDENSER NOTE: When replacing condenser, always replace "O" rings and snap-on connections. Removal & Installation 1) Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect air intake hose.
  • Page 33 Fig. 19: Removing Damper Motor Courtesy of Volvo Cars of North America. DASHBOARD NOTE: Dashboard consists of 5 main sections: upper frame, lower frame (left and right), defroster duct and dashboard cover. Except for dashboard cover, all the main sections are glued together and cannot be separated.

  • Page 34: Dashboard Cover

    See DASHBOARD. Remove climate control unit. See CLIMATE CONTROL UNIT. Remove evaporator cover screws and clips. Lift out evaporator. See Fig. 20. To install, reverse removal procedure. Fig. 20: Removing Evaporator Courtesy of Volvo Cars of North America. HEATER CORE...

  • Page 35: Receiver-Drier

    To install, reverse removal procedure. Fig. 21: Removing Heater Core Courtesy of Volvo Cars of North America. RECEIVER-DRIER Removal & Installation 1) Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect air intake hose and remove hose connector to fan cover.

  • Page 36: Wiring Diagrams

    hose connector to fan cover. Remove fan cover. Disconnect relays and wires from fan cover. Remove 4 screws from fan cover and remove relay casing and spacers. Disconnect 2-pin connector from fan relay and connector from fan motor. Remove fan cover. See Fig. 18. 3) Shield radiator.
  • Page 37 Fig. 22: Wiring Diagram (850 2.3L Turbo - 1 Of 2)
  • Page 38 Fig. 23: Wiring Diagram (850 2.3L Turbo - 2 Of 2)
  • Page 39 Fig. 24: Wiring Diagram (850 2.4L - 1 Of 2)
  • Page 40 Fig. 25: Wiring Diagram (850 2.4L - 2 Of 2)

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1995 850

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